Casting production of coils for electrical machines

Groninger, Michael; Horch, Felix; Kock, Alexander; Pleteit, Hermann; Ponick, Bernd; Schmidt, David C.; Wöstmann, Franz Josef

doi:10.1109/edpc.2011.6085534

Cited by 14 publications

(4 citation statements)

References 1 publication

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“…The dimensional accuracy of the AM process would allow the production of multilayer windings applicable to electrical machines, transformers and inductors if the electrical insulation could be reliably applied. The AM process is an expensive manufacturing method at present, however, casting technology could be used as an alternative production method with similar geometric freedom, [27], [28]. This paper has demonstrated a significant reduction in AC winding loss through the use of shaped windings.…”

Section: Discussionmentioning

confidence: 83%

Additive manufacturing of shaped profile windings for minimal AC loss in gapped inductors

Simpson

Mellor

2017

2017 IEEE International Electric Machines and Drives Conference (IEMDC)

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Section: Discussionmentioning

confidence: 83%

Additive manufacturing of shaped profile windings for minimal AC loss in gapped inductors

Simpson

Mellor

2017

2017 IEEE International Electric Machines and Drives Conference (IEMDC)

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“…As an alternative to the mentioned winding topologies, there are also other uncommon winding topologies studied in the literature. For example, in [8,9], casting production of electric machine windings is proposed; however, similar to hairpin windings, they also suffer from elevated AC losses. Lomheim in [10] presents a winding design, which is manufactured from 4-mm-thick copper using water jet.…”

Section: Introductionmentioning

confidence: 99%

Flat winding made of aluminum or copper sheet for axial flux machines

Cakal

Keysan

2021

IET Electric Power Appl

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A novel flat winding topology has been proposed as an alternative to conventional windings with stranded round wires and other bar wound windings. The proposed winding is manufactured from thin conductor sheets by industrial tools such as stamping press, laser cutter, or water jet. As these tools are widely used in the production of electric machines, the flat winding topology can provide ease of manufacturing without significant modification to the production line. Besides, superior current ratings, shortened end windings, and high fill factors are other advantages of flat winding. Its performance is measured by comparison study between flat wired prototype machine and the stranded wired machines with similar ratings presented in the literature. The proposed winding is implemented on an axial flux permanent magnet machine. Analytical modeling is presented, including field modeling, voltage, torque derivations, and loss modeling. Then, experimental verification of a 1.4‐kW and 26‐Nm prototype with copper and aluminum flat windings is presented, and the performances of two are compared.

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“…Shaped windings have been achieved using round wire wound on to forming bobbins, [9], by the use of pre-cut foil windings, [10], [11], through stacking a series of Printed Circuit Boards (PCBs) which are electrically connected in the end-winding or using solid busbar arrangements, [12]- [14]. More recently metal casting techniques have been explored, [15], [16], and the use of metal Additive Manufacturing (AM) methods have been demonstrated which offer unparalleled geometric freedom in conductor shape and layout, Fig. 1, and can allow additional features such as cooling channels and terminals to be built directly into the part, [17]- [21].…”

Section: Introductionmentioning

confidence: 99%